Strap mount for solar panels

ABSTRACT

A novel solar panel mounting system including a strap and one or more supports, having top flanges, attached to each other. The strap is attached between a first point and a second point on a surface. The mounting system is designed to support a solar panel on this surface. The top flange of the support may be parallel to or at an angle to the surface. The strap may be singular or comprised of two straps one above the other. The strap may be attached to the top flange or the bottom or both. The supports may have any cross sectional shape. The strap may be attached to the support at its end or at a distance from the end; or normal to the support or at an angle to it. The length of the support is greater than the width of the strap.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a divisional of U.S. patent application Ser. No. 13/038,286, filed Mar. 1, 2011, now allowed, the entire specification, claims and drawings of which are hereby incorporated into this Application by reference.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to the field of solar panels and more particularly to apparatuses and methods for mounting solar panels on surfaces, including roofs, walls and the ground.

(2) Description of the Related Art

Solar panels must be mounted correctly in order to maximize power production and prevent movement of the panels from the force of wind. The proper solar panel mounting provides stability and the proper directional and latitudinal orientation for the solar array.

Different mounting systems are available depending on whether the modules will be mounted on a roof, a wall, the ground, or a pole. For mounting on a roof or the ground there are ballast mounts, flush mounts (such as Modular IronRidge XRS available from IronRidge in Willits, Calif.) standing seams mounts, and adjustable mounts (such as those available from Unirac in Albuquerque, N. Mex.). These usually include a tilted rack, firmly attached to the substrate surface, on which the modules are firmly mounted; or brackets of at least two different heights, firmly attached to the substrate surface, to which the ends of the modules are firmly attached.

Such systems are heavy and expensive to fabricated and time consuming to install. What is needed is a mounting system which is cheaper to fabricate and less time consuming to install. Preferably the improved system can be easily fabricated on site or provided as a kit.

Development of a solar panel mounting system which is cheaper to fabricate and less time consuming to install represents a great improvement in the field of solar panel mounting and satisfies a long felt need of the solar panel installer and owner.

SUMMARY OF THE INVENTION

The present invention is a novel solar panel mounting system. It includes a strap and a support attached to each other. The strap is attached between a first point on a surface and a second point on a surface. The points are spaced apart from each other. The support is designed to support a solar panel on the surface, between the upper and lower sides of the solar panel. The support has a top flange, a bottom and an end.

The mounting system may be fabricated on site or provided as a kit. First the strap and support are fabricated. Then the strap is attached to the surface and the support is attached to the strap.

The top flange may be parallel to the surface or at an angle to the surface. The strap may be attached to the top flange or the bottom. Alternatively the strap may comprise a first strap above a second strap. In this case the first strap is attached to the top flange and the seconds strap is attached to the bottom. In addition the support may comprise a first support and a second support spaced apart from each other.

The supports may have any cross sectional shape, including, Z, C, Π, inverted Π, inverted T, and I. The strap may be attached to the support at its end or at a distance from the end. The strap may be attached to the support normal to the support or at an angle to it. The length of the support is greater than the width of the strap. The cross section of the strap may be rectangular or have any shape such as a C, Z or I. In addition, the top surface of the strap may be curved up or down.

This invention, therefore, is a solar panel mounting system which is cheaper to fabricate and less time consuming to install. The advantages of installation of this invention are decreasing the number of attachment points, transfer of loads by use of the straps or cables, and faster installation with fewer parts. This invention provides less wind resistance and uplift. This improved system can be easily fabricated on site or provided as a kit.

An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and description of a preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side, cross sectional view of slightly more than one unit of one embodiment of this invention installed on a surface and supporting a solar panel. This embodiment has a top strap and a bottom strap and two supports and is attached to the surface joists.

FIG. 2 is an enlarged view of the area indicated by the rectangle 2 on FIG. 1.

FIG. 3 is an enlarged view of the area indicated by the rectangle 3 on FIG. 1.

FIG. 4 is an enlarged view of the area indicated by the rectangle 4 on FIG. 1.

FIG. 5 is a side, cross sectional view of one unit of another embodiment of this invention. This embodiment has a bottom strap and two supports.

FIG. 6 is a side, cross sectional view of slightly more than one unit of yet another embodiment of this invention installed on a surface and supporting a solar panel. This embodiment has a top strap and two supports.

FIG. 7 is a perspective view of an embodiment of this invention installed on a surface for support of a solar panel array from one angle.

FIG. 8 is a perspective view of this invention installed on a surface for support of a solar panel array from another angle.

FIG. 9A is a sketch from the top of this invention illustrating one variation in attachment of the top support.

FIG. 9B is a sketch from the top of this invention illustrating another variation in attachment of the top support.

FIG. 9C is a sketch from the top of this invention illustrating yet another variation in attachment of the top support.

FIG. 9D is a sketch from the top of this invention illustrating yet another variation in attachment of the top support.

FIG. 9E is a sketch from the top of this invention illustrating yet another variation in attachment of the top support.

FIG. 10 is a side, cross sectional view of slightly more than one unit of one embodiment of this invention installed on a surface and supporting a solar panel. This embodiment has a top strap and a bottom strap and two supports and is attached to the surface and not to the joists.

FIG. 11A is a cross sectional sketch illustrating this invention with two vertical supports of equal height. The top flanges point towards the sides of the solar panel.

FIG. 11B is a cross sectional sketch illustrating this invention with two supports at the same angle to the vertical yet normal to the solar panel, of different heights. The top flanges point towards the sides of the solar panel.

FIG. 11C is a cross sectional sketch illustrating this invention with two supports at different angles to the vertical and to the solar panel, of different heights. The top flanges point towards the sides of the solar panel.

FIG. 11D is a cross sectional sketch illustrating this invention with two supports at the same angle to the vertical yet normal to the solar panel, of different heights. The top flanges point away from the sides of the solar panel.

FIG. 12 shows attachment of straps to the ground with a pin or peg.

The supports in FIGS. 1-12 are all zig-zag shaped. FIGS. 13A-13D illustrate various other shapes that the supports can have.

FIG. 13A illustrates a support with a C shape.

FIG. 13B illustrates a support with an angled Π shape.

FIG. 13C illustrates a support with an inverted T shape.

FIG. 13D illustrates a support with an angled I shape.

FIG. 13E illustrates a support with an inverted, angled Π shape.

FIG. 13F illustrates a support with an inverted Π shape.

FIG. 14 is a side, cross sectional view of slightly more than one unit of one embodiment of this invention installed on a roof and supporting a solar panel. This embodiment has a top strap, and a single, angled, Π shaped support and is attached to the roof joists.

FIG. 15A is a cross sectional view of a strap having a rectangular cross section.

FIG. 15B is a cross sectional view of a strap having a C-shaped cross section.

FIG. 15C is a cross sectional view of a strap having a reverse C-shaped cross section.

FIG. 15D is a cross sectional view of a strap having a Z-shaped cross section.

FIG. 15E is a cross sectional view of a strap having an I-shaped cross section.

FIG. 16A is a cross sectional view of a strap having a rectangular cross section and a concave top surface.

FIG. 16B is a cross sectional view of a strap having a C-shaped cross section and a concave top surface.

FIG. 16C is a cross sectional view of a strap having a reverse C-shaped cross section and a convex top surface.

FIG. 16D is a cross sectional view of a strap having a Z-shaped cross section and a concave top surface.

FIG. 16E is a cross sectional view of a strap having an I-shaped cross section and a convex top surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.

FIGS. 1, 2, 3 and 4 illustrate the main features of this invention 10. This invention is an apparatus and method for mounting solar panels 14 on a surface. Solar panels 14 have an upper side 18 and a lower side 22. Depending on orientation, the sides 18, 22 can be the lengths or widths of the panels 14. Surfaces on which this invention can be used include roofs 26, walls and the ground 30.

The invention includes a support 34 supporting each solar panel 14 to the surface. The support 34 is located between the upper 18 and lower sides 22 of each solar panel 14. Preferably the supports 34 have at least one central member 38 and a top flange 42. The top flange 42 can be parallel to or at an angle to the surface. If angled, the angle α between the top flange 42 and the central member 38 is the complement of the angle β between the surface and the bottom 46 of the solar panel 14. The angle β is preferably 45° or less.

This invention also includes a strap 58 attached between a first point 62 and a second point 66 on the surface. The first 62 and second 66 points are spaced apart from each other on either side of the support 34. Preferably, in buildings, the invention is designed so that attachment of the strap 58 to the roof 26 or wall at the points 62, 66 is over a roof joist 70 or beam so that attachment is made through the roof 26 and into the joist 70 or through the wall and into the beam. Preferably such attachment is made by screws, bolts, or studs.

The strap 58 can be attached to the top flange 42, as shown in FIG. 6, or the bottom 50 of the support 34, as shown in FIG. 5. In the former case, the strap will have a steeply pitched section 74 and a gently pitched section 78. But the strap 58 can comprise a top or first strap 58 a over a bottom or second strap 58 b, as shown in FIGS. 1-4. In this case the top strap 58 a is attached to the top flange 42 (and will have a steeply pitched section 74 a and a gently pitched section 78 a) and the bottom strap 58 b is attached to the bottom 50 of the support 34. Attachment to the top flange 42 can be by and convenient means such as screws, bolts, studs, clamps or welding. Many different ways can be conceived of attaching the bottom 50 of each support 34 to bottom strap 58 b. Perhaps, the simplest is via a bottom flange 54 attached to the central member 38. Fastening may be via screw, bolt, stud, adhesive, clamping, welding, etc. In addition, the bottom 50 of each support 34 may be attached to the surface.

The support 34 can comprise two supports, a peak support 34 a and an intermediate support 34 b spaced apart from each other, as shown in FIGS. 1, 3, 4, 5, 6 and 7. The supports 34 a 34 b can be provided with weep holes 76 to allow drainage and prevent water from collecting and stagnating. In windy areas, the supports can be provided with pressure relief holes (not illustrated) to prevent wind from blowing them off the surface.

Preferably the straps 58 a, 58 b are a few inches wide W and made of metal. In fact, the straps 58 a, 58 b could be metal cable. On the other hand the lengths L of the peak and intermediate supports must be at least as long as the width or length of the solar panels, depending on the orientation. In fact they may be multiples of the width or length of the solar panels. FIGS. 7 and 8 illustrate the widths of the straps and the lengths of the supports. The solar panels are preferably attached to the top flanges 42 of the supports 34, 34 a, 34 b.

The cross sections of the straps 58 do not have to be rectangular as shown in FIG. 15A. They could alternatively have any cross sectional shape. Some examples are shown in FIGS. 15B-15E.

FIG. 15B illustrates a strap having a C-shaped cross section.

FIG. 15C illustrates a strap having a reverse C-shaped cross section.

FIG. 15D illustrates a strap having a Z-shaped cross section.

FIG. 15E illustrates a strap having an I-shaped cross section.

Moreover, the top surfaces 60 of the straps 58 could be curved rather than flat as illustrated in FIG. 15A. Some examples are shown in FIGS. 16A-16E. FIGS. 16A, 16B, and 16D illustrate concave surfaces 60 while FIGS. 16C and 16E illustrate convex surfaces 60. Other surfaces of the straps 58 could be curved similarly.

There are a multitude of other variations of this invention. FIG. 7 shows the usual case in which the top 58 a and bottom 58 b straps run normal to the supports 34 a, 34 b at their ends 82 a, 82 b. FIG. 9A-9E are sketches from the top of this invention illustrating variation in attachment of the top straps 58 a. In all of FIGS. 9A-9D, the straps 58 a run at an angle to the supports 34 a, 34 b. While particular angles are shown, it will be obvious that there can be considerable variation on the angle. In FIG. 9A the gently pitched and steeply pitched sections meet at the peak support and the angles that the steeply pitched 74 a and gently pitched 78 a sections make with the supports 34 a, 34 b are supplementary to each other. In FIG. 9B the gently pitched 78 a and steeply pitched 74 a sections are separated at the peak support 34 a. In FIG. 9C the gently pitched sections 78 a only run to the supplementary support 34 b and the steeply pitched sections 74 a only run to the peak support 34 a. In FIG. 9D the top straps 58 a run straight from the first point 62 on one end 86 of the solar panel 14 to the second point 66 on the other end 90 of the solar panel 14 and vice versa. It will be obvious that the bottom straps 58 b can also run straight from the first point 62 on one end 86 of the solar panel 14 to the second point 66 on the other end 90 of the solar panel 14 and vice versa. Many other variations of these schemes, including their combinations are possible. For example see FIG. 9E. Moreover, the straps 58 a, 58 b do not have to be straight. They can be curved, trace a zigzag path, trace a sinusoidal path, etc.

FIG. 10 illustrates how this invention 10 can be attached to the surface and not just to the joists 70 or beams. The embodiment illustrated has a top strap 58 a and a bottom strap 58 b, a peak support 34 a and a supplemental support 34 b. However, this means of surface attachment can be applied to any embodiment or variation of this invention; for example, those shown in FIGS. 5, 6 and 14

In the usual case the peak 34 a and supplemental 34 b supports are normal to the surface 94 and the peak support 34 a is taller than the supplemental support 34 b, as illustrated in FIGS. 1, 5, 6 and 7. But this does not have to be the case. FIGS. 11A-11D illustrate some variations on this theme. FIG. 11A shows the peak 34 a and supplemental 34 b supports normal to the surface 94 and of equal height. The top flanges 42 point towards the sides 18, 22 of the solar panel 14. FIG. 11B shows the peak 34 a and supplemental 34 b supports at the same angle to the surface 94 yet normal to the solar panel 14, of different heights. The top flanges 42 point towards the sides 18, 22 of the solar panel 14. FIG. 11C shows the peak 34 a and supplemental 34 b supports at different angles to the surface 94 and to the solar panel 14, of different heights. The top flanges 42 point towards the sides 18, 22 of the solar panel 14. FIG. 11D shows the peak 34 a and supplemental 34 b supports at the same angle to the surface 94 yet normal to the solar panel 14, of different heights. The top flanges 42 point away from the sides 18, 22 of the solar panel 14. Many other variations of these schemes, including their combinations are possible. Moreover, the supports 34 a, 34 b do not have to be straight. They can be curved, trace a zigzag path, trace a sinusoidal path, etc.

FIG. 12 shows attachment of straps 58 a, 58 b to the ground 30 with a pin or peg 98. The pin 98 is rammed or hammered into the ground 30 and retains the invention 10 in a manner similar to the retention of a tent with a tent peg.

The supports 34 a or 34 bs in FIGS. 1-12 are all zig-zag shaped. FIGS. 13A-13D illustrate various other shapes that the supports 34 a or 34 bs can have.

FIG. 13A illustrates a support 34 a or 34 b with a C shape, including an angled top flange.

FIG. 13B illustrates a support 34 a or 34 b with an angled Π shape.

FIG. 13C illustrates a support 34 a or 34 b with an inverted T shape.

FIG. 13D illustrates a support 34 a or 34 b with an I shape and an angled top flange.

FIG. 13E illustrates a support 34 a or 34 b with an inverted, Π shape with angled top flanges.

FIG. 13F illustrates a support 34 a or 34 b with an inverted Π shape and parallel top flanges.

FIG. 14 is a side, cross sectional view of slightly more than one unit of one embodiment of this invention 10 installed on a roof 26 and supporting a solar panel 14. This embodiment has a top strap 58 a, and a single, angled, Π shaped support 34 and is attached to the roof joists 70.

This novel mounting system 10 may be fabricated on site or provided as a kit. First the strap 58 and support 34 are fabricated. Then the strap 58 is attached to the surface 94 between the two points 62, 66 and the support 34 is attached to the strap 58. Finally the solar panel 14 is attached to the top flange 42 of the support 58.

Preferably, there is a peak support 34 a and an intermediate support 34 b. Preferably there is a top strap 58 a and a bottom strap 58 b. In this case, the bottom strap 58 b is attached to the surface 94 between the two points 62, 66. If the surface is a roof 26 or wall, such attachment is made by screws, bolts, or studs and preferably into underlying joists 70 or beams. If the surface is the ground 30, attachment is made means of driven pins or pegs 98.

Then the supports 34 a, 34 b are attached to the bottom strap 58 b, preferably via their bottom flanges 54. Attachment may be via screw, bolt, stud, adhesive, clamping, welding, etc. In addition, the bottom 50 of each support 34 may be attached to the surface.

Next the top strap 58 a is run over the tops of the supports 34 a, 34 b and attached to their top flanges 42. Attachment is preferably made via screw, bolt, stud, or clamping. Finally, the solar panels are positioned and attached to the top flanges 42. Attachment is preferably made via screw, bolt, stud, or clamping.

There are at least 48 variations of this invention 10. The support can be singular 34 or in two parts 34 a, 34 b. The strap can be at the top 58 a, at the bottom 58 b or both. The top strap 58 a can be normal to the supports 34 a, 34 b or at an angle to them. The top strap 58 a can be continuous and or in two separate parts. In addition there are many possible patterns for attaching the bottom strap 58 b between the two points 62, 66.

The following reference numerals are used on FIGS. 1 through 14:

-   -   10 novel solar mounting system of this invention     -   14 solar panel     -   18 upper side of solar panel     -   22 lower side of solar panel     -   26 roof     -   30 ground     -   34 support     -   34 a peak support     -   34 b intermediate support     -   38 central member of support     -   42 top flange of support     -   46 bottom of solar panel     -   50 bottom of support     -   54 bottom flange of support     -   58 strap     -   58 a top or first strap     -   58 b bottom or second strap     -   60 top surface of strap     -   62 first point on surface     -   64 bottom surface of strap     -   66 second point on surface     -   70 joist or beam     -   74 steeply pitched section of strap     -   74 a steeply pitched section of top strap     -   76 weep hole     -   78 gently pitched section of strap     -   78 a gently pitched section of top strap     -   82 a one end of support     -   82 b other end of support     -   86 one end of solar panel     -   90 other end of solar panel     -   94 surface     -   98 pin or peg     -   α angle between the top flange and the central member     -   β angle between the surface and the bottom of the solar panel     -   W width of strap     -   L length of support

Thus, the present invention has been described herein with reference to particular embodiments for particular applications. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof.

It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention. 

What is claimed is:
 1. An apparatus for mounting a solar panel on a surface comprising: a) a strap having a bottom surface; b) a support having a top flange, and a bottom flange; said bottom surface attached to said top flange with a fastener; said bottom flange attached to said surface with a fastener; c) a first attachment attaching said strap to said surface with a fastener at a first point on said surface; and d) a second attachment attaching said strap to said surface with a fastener at a second point on said surface; said first and second points being spaced apart; said support being between said first and second points; whereby said strap is divided into a steeply pitched section and a gently pitched section; said gently pitched section for mounting said solar panel.
 2. An apparatus as claimed in claim 1 in which said top flange is parallel to said surface.
 3. An apparatus as claimed in claim 1 in which said top flange is at an angle to said surface.
 4. An apparatus as claimed in claim 1 in which the cross section of said strap is rectangular.
 5. An apparatus as claimed in claim 1 in which said support comprises a first support and a second support spaced apart from each other.
 6. An apparatus as claimed in claim 5 in which the cross-section of said first support is a zig-zag shape.
 7. An apparatus as claimed in claim 5 in which the cross-section of said second support is a zig-zag shape.
 8. An apparatus as claimed in claim 1 in which the cross-section of said support is a zig-zag shape.
 9. An apparatus as claimed in claim 1 in which the length of said support is greater than the width of said strap.
 10. A method of fabricating an apparatus for mounting a solar panel on a surface comprising the steps of: a) providing a strap having a bottom surface; b) providing a support having a top flange and a bottom flange; c) attaching said bottom flange to said surface with a fastener; d) attaching said bottom surface to said top flange with a fastener; e) attaching said strap to a first point on said surface and a second point on said surface with fasteners; said points being spaced apart; said support being between said first and second points; whereby said strap is divided into a steeply pitched section and a gently pitched section; said gently pitched section for mounting said solar panel.
 11. A method as claimed in claim 10 in which said top flange is parallel to said surface.
 12. A method as claimed in claim 10 in which said top flange is at an angle to said surface.
 13. A method as claimed in claim 10 in which the cross section of said strap is rectangular.
 14. A method as claimed in claim 10 in which said support comprises a first support and a second support spaced apart from each other.
 15. A method as claimed in claim 14 in which the cross-section of said first support is a zig-zag shape.
 16. A method as claimed in claim 14 in which the cross-section of said second support is a zig-zag shape.
 17. A method as claimed in claim 10 in which the cross-section of said support is a zig-zag shape.
 18. A method as claimed in claim 10 in which the length of said support is greater than the width of said strap. 